Dang that Weber Kettle handle is
Not more plastic Weber Kettle handles - it's for
Picture 1: Hot Weber kettle lid
Picture 2: The solution to
the Weber kettle lid handle
Picture 3: Closeup of my Weber
kettle lid handl mod
The good old days of wood handled lids on the Weber kettle
are long gone. In it's place are the plastic jobs that really
hold the heat. They get too darn hot to work without a glove.
Forget that - I smell a mod coming on.
The wire spring type handles are used with success in many
BBQ and grill applications. Fitting one to the Weber kettle lid
handle would be a fun project.
I purchased 3 spring handles on-line. I only needed to
retrofit one Weber kettle, but 3 would give me some wiggle
room, letting me cut, grind, and modify springs until I found a
proof of concept.
If you remove the screws that hold on the plastic handle,
you wind up with a simple metal strip that is spot welded to
the lid. The plastic handle is designed to attach to this metal
strip with one screw.
The problem is that there's no way to get the spring onto
the handle without cutting the metal strip. Once cut,
you need a way of repairing the cut so you don't wind up
In this mod, I took a piece of 3/4 inch wide x 1/8 thick
cold roll steel stock. I made the piece you see in these
pictures. It helps retain the spring which is under pressure in
this application. Screws repair the cut in the original handle
A bench vice break helped me make the bends - which were
spaced so's to match where the spring would but up against the
original strip of handle metal - meaning the spring would be
retained top and bottom.
Installing these bits was very difficult, and took a lot of
patience and finesse. To do it over again, I would have tapped
a thread in the holes of the lid handle metal strip, instead of
using hex nuts to bolt it all up.
The results of this modification are very positive. Gloves
are no longer needed to handle this lid. The handle remains
cool to the touch no matter how hot a cook you're doing. A nice